Tracker Off-Road 500S Service Manual page 99

PK201A
2. Connect the upper and lower coolant hoses to the
radiator and secure with the appropriate hose clamps;
then connect the cooling fan wire connector to the
main harness. Connect the reservoir hose (B) to the
right side of the filler neck and the bleed hose (A) to
the back side of the radiator filler neck.
PK198A
PK197
3. Pour the recommended coolant into the radiator and
reservoir tank. Bleed the cooling system (see Liquid
Cooling System).
4. Start the engine and warm up to operating tempera-
ture. Allow the engine to completely cool to room
temperature; then verify the coolant level is at the
bottom of the stand pipe in the radiator neck. Check
coolant level in reservoir tank. Add coolant as neces-
sary.
5. Install both skid plates, radiator access panel, and
front hood.
THERMOSTAT
Removing
1. Drain approximately one quart of coolant from the
cooling system.
2. Remove the two cap screws securing the thermostat
housing to the bracket. Account for a thermostat with
seal and O-ring installed in the thermostat housing
cover.
PK202A.
Inspecting
1. Inspect the thermostat for corrosion, wear, or spring
damage.
2. Using the following procedure, inspect the thermo-
stat for proper operation:
A. Suspend the thermostat in a container filled with
water. Do not allow the thermostat to contact the
container.
B. Heat the water and monitor the temperature with
a thermometer.
C. The thermostat should start to open at 176-183°F
(80-84°C) and be fully open at 203°F (95°C).
Minimum valve lift is approximately 8 mm (0.03
in).
D. If the thermostat does not open, it must be
replaced. If the thermostat does not close at room
temperature, it must be replaced.
3. Inspect all coolant hoses, connections, and clamps
for deterioration, cracks, and wear.
 NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.
Installing
1. Place the thermostat into the housing; then lightly
grease the O-ring in the housing cover. Place the
cover onto the thermostat housing; then secure the
assembly to the bracket. Secure the cap screws.
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